Interfacial Phenomena in Multi-Micro-/Nanolayered Polymer Coextrusion: A Review of Fundamental and Engineering Aspects

The multilayer coextrusion process is known to be a reliable technique for the continuous fabrication of high-performance micro-/nanolayered polymeric products. Using laminar flow conditions to combine polymer pairs, one can produce multilayer films and composites with a large number of interfaces at the polymer-polymer boundary. Interfacial phenomena, including interlayer diffusion, interlayer reaction, interfacial instabilities, and interfacial geometrical confinement, are always present during multilayer coextrusion depending on the processed polymers. They are critical in defining the microstructural development and resulting macroscopic properties of multilayered products. This paper, therefore, presents a comprehensive review of these interfacial phenomena and illustrates systematically how these phenomena develop and influence the resulting physicochemical properties. This review will promote the understanding of interfacial evolution in the micro-/nanolayer coextrusion process while enabling the better control of the microstructure and end use properties.

Critical Role of Interfacial Diffusion and Diffuse Interphases Formed in Multi-Micro-/Nanolayered Polymer Films Based on Poly(vinylidene fluoride) and Poly(methyl methacrylate)

It is known that the macroscopic properties of multilayer polymer films are largely dominated by the diffuse interphase formed via interfacial diffusion between neighboring layers. However, not much is known about the origin of this effect. In this work, we reveal the role of interfacial diffusion and the diffuse interphase development in multilayer polymer films, based on a compatible poly(vinylidene fluoride)/poly(methyl methacrylate) system fabricated by forced-assembly micro-/nanolayer coextrusion. Interestingly, the layer morphology is found to prevail in all investigated multilayer films, even for the nanolayered system where the interdiffusion is substantial. It is also demonstrated that, in the presence of macromolecular and geometrical confinements, interfacial diffusion significantly alters the crystalline morphology and microstructure of the resulting micro-/nanolayered films, which leads to quantitatively different dielectric and rheological properties. More importantly, the combination of dielectric relaxation spectroscopy and energy-dispersive X-ray analysis further reveals that multiple diffuse interphases with various length scales exist in the multilayer structures. The presence of these multiple interphases is explained in terms of a proposed physical picture for the interdiffusion of fast-mode mechanism occurring in the coextrusion process, and their length scales (i.e., interphase thicknesses) are further mapped quantitatively. These findings provide new insights into the effects of interfacial diffusion and diffuse interphases toward tailoring interfaces/interphases in micro-/nanolayered polymer structures and for their advanced applications.

Three-dimensional viscoelastic numerical analysis of the effects of gas flow on L-profiled polymers in gas-assisted coextrusion

In this study, polymer gas-assisted coextrusion experiments were performed. The influence of a traditional coextrusion flow zone on the gas groove and the relationship between the gas pressure and the melt flow rate were studied. To determine the effects of the gas flow on gas-assisted coextrusion, a three-dimensional simulation was developed in which the gas layer was considered as an independent flow zone. The influence of the gas pressure, gas layer thickness and melt flow rate on the melts’ profile and the deflection deformation degree (DDD) was studied, and the relationship between the gas pressure, gas layer thickness and melt flow rate was obtained. The numerical results indicated that a traditional coextrusion flow zone in front of a gas-assisted coextrusion flow zone could allow products to avoid a gas groove. The quality of the products could be improved by decreasing the gas pressure and gas layer thickness or increasing the melt flow rate. Additionally, the minimum gas pressure decreased as the gas layer thickness increased and increased as the melt flow rate increased. The numerical results were in good agreement with the experimental results, despite a slight quantitative error. Therefore, reasonably controlling the gas flow condition is key in practical applications of gas-assisted coextrusion, and the effects of the gas layer should be considered in gas-assisted coextrusion simulations.

Interfacial Diffusion and Bonding in Multilayer Polymer Films: A Molecular Dynamics Simulation

As a stacked form of ultrathin polymer films, multilayer nanostructures are of great interest in various applications. Coarse-grained molecular dynamics simulations were carried out to understand the behaviors of interfacial diffusion and bonding of multilayer polymer films. We found two obvious stages for the interfacial diffusion of polymers in the multilayer film, and it is 3 times faster in the first stage than in the second one due to the evolution of molecular conformations. The polymers near the interfaces have an in-plane mobility much higher than the out-of-plane one. The strength of interfacial bonding has been characterized by the fast tensile stress-strain curve along the normal direction. It shows multiple yielding points for the multilayer polymer films, which is distinct from the tensile behavior of the bulk. The ultimate tensile stress (UTS) and corresponding separating strain, surprisingly, do not necessarily increase with diffusion time. Because of the dramatic molecular rotation and extension during the first stage of interfacial diffusion, the interlayer interpenetration is nonuniformly distributed in the plane of the interface. Such a nonuniform distribution may be one of the reasons for the decrease of the UTS and separating strain.

Synergistic effect of PLA–PBAT–PLA tri-block copolymers with two molecular weights as compatibilizers on the mechanical and rheological properties of PLA/PBAT blends

Systematic study on the synergistic effects of different molecular-weight PLA–PBAT–PLA tri-block copolymers on the mechanical and rheological properties of PLA/PBAT blends.